Technical Field
[0001] This invention relates to an area cutting method and, more particularly, to an area
cutting method for cutting an area bounded by a predetermined curve of an external
shape by moving a tool along a cutting path in a first direction to perform machining,
positioning the tool at a machining starting point on the next cutting path, which
is shifted from the above-mentioned cutting path a predetermined amount in a second
direction, after the completion of machining along the abovementioned cutting path,
thereafter moving the tool along the next cutting path in the first direction to perform
machining, and thereafter repeating such unidirectional cutting.
Background Art
[0002] Forms of numerically controlled machining include cutting in which the interior of
an area bounded by the curve of an external shape is hollowed out down to a predetermined
depth, and die milling in which the interior of an area is die milled. In such cutting
of the interior of an area, the process includes (a) entering the curve OLC of an
external shape of an area AR shown in Fig. 1(A), cutting direction (direction of arrow
A), cut-in direction (direction of arrow B), and cut-in pitch P, (b) creating a cutting
path PT on the basis of the entered data, (c) performing cutting by moving a tool
TL in the cutting direction along the created cutting path PT
i from the machining starting point P
i to the machining end point Q. on the cutting path PT
i, (d) raising the tool a predetermined amount along the Z axis in the rapid-traverse
mode after the completion of cutting along the abovementioned cutting path [see Fig.
1(B)], (e) moving the tool in the rapid-traverse mode to a point directly above a
machining starting point P
i+1 on the next cutting path PT
i+1, which is shifted in the cutting direction by the pitch P, after the completion of
the raising operation, (f) then moving the tool in the cutting-feed mode along the
-Z axis to the machining starting point P
i+1' and (g) thereafter performing cutting by moving the tool TL in the cutting direction
from the machining starting point P
i+1 to the machining end point Q
i+1 on the cutting path PT
i+1, and subsequently repeating these unidirectional cutting motions to machine the area
AR. Further, (h) when the amount remaining in the cut-in direction (direction of arrow
A) is less than the pitch P, the tool is moved along the curve OLC of the external
shape in the cutting feed mode to remove the uncut portion. It should be noted that,
for each cutting path PT
i (i = 1, 2, ...), two points P
i, Q
i where a straight line SL
i decided by the cut-in direction and pitch P intersects an offset curve OFC that takes
finishing tolerance t and cutter radius r a into account are specified as machining
starting and end points, respectively.
[0003] A tool referred to as an end mill is used as the tool. As shown in Fig. 2, an end
mill includes a bottom surface having cutting edges BTl, BT2, and a cutter side having
a cutting edge BT3. Longitudinal cutting is performed by the cutting edges BTl, BT2,
and transverse cutting is carried out by the cutting edge BT3. Little cutting force
is applied in the longitudinal direction, and great cutting force in the transverse
direction. The workpiece is a solid material prior to the cutting of an area. Moreover,
the center position CP (see Fig. 2) of the bottom surface of tool (end mill) TL does
not rotate (i.e., is stationary) even when the tool TL is rotated. Consequently, when
the initial cut is to be made, even though the tool TL is moved for cutting feed from
an approach starting point P
a, which is located directly above the cutting starting point P
s shown in Fig. 3, toward the cutting starting point P while being rotated, the tool
TL slides along the surface of the workpiece WK rather than cutting into the workpiece
or, even if it does cut into the workpiece, it fails to do so smoothly and results
in a machining error. Accordingly, it is arranged to move the tool TL in the cutting-feed
mode from a position P
a', which is displaced from a point directly above the cutting starting point P , toward
the cutting starting point P along an oblique path, as shown by the one-dot chain
line in Fig. 3, whereby the tool cuts into the workpiece smoothly.
[0004] When the tool TL is moved along the (i+l)th cutting path PT
i+1 in the conventional area machining method by unidirectional cutting, the tool travels
while slightly overlapping the area A
i (see Fig. 4) already cut by tool movement along the i-th cutting path PT.. However,
the amount of overlap is small. Therefore, unless some consideration is given to this
when positioning the tool at the machining starting point P
i+l on the cutting path PT
i+1, the tool will not bite into the workpiece satisfactorily, just as when the tool
was moved with respect to the solid material. According to the conventional method,
therefore, after the tool is positioned directly above the machining starting point
P
i+l in the rapid-traverse mode, the tool is moved toward the machining starting point
P
i+1 at low-velocity cutting feed so that the tool will bite into the workpiece. With
this method, however, the time needed to machine an area is lengthened because the
tool must be moved at low-velocity cutting feed toward each machining starting point
on numerous cutting paths. Machining time is prolonged even further with the conventional
method since it is necessary to cut away the uncut portion [the shaded portion in
Fig. 1(A)] by finally moving the tool along the curve of the external shape.
[0005] Accordingly, an object of the present invention is to provide an area cutting method
whereby an area can be machined while repeating machining along a cutting path in
one direction and machining along parts of a curve of an external shape.
[0006] Another object of the present invention is to provide an area cutting method for
moving a tool in the cutting-feed mode along a curve of an external shape from a machining
end point Q
i on a cutting path PT
i just cut to a machining end point Q
i-1 on a cutting path PT
i-1 cut last, thereafter moving the tool in the rapid-traverse mode to a machining starting
point P on the cutting path PT., then moving the tool in the cutting-feed mode along
the curve of the external shape from P
i to a machining starting point P
i+1 on the next cutting path PT
i+1, and subsequently repeating the above-described cycle to perform area cutting, whereby
all movement (retraction motion, approach motion) along the Z axis is performed in
the rapid-traverse mode and final tool movement along the curve of the external shape
is dispensed with without leaving uncut portions.
Disclosure of the Invention
[0007] The present invention provides an area cutting method for machining the interior
of an area bounded by a curve of a predetermined external shape. The area cutting
method has a step, executed after completion of cutting along a cutting path PT
i, of moving a tool in the cutting-feed mode along a curve OLC of an external shape
from a machining end point Q
i on a cutting path PT
i to a machining end point Q
i-1 on a cutting path PT
i-l cut last, a step of positioning the tool at a machining starting point P
i on the cutting path PT
i, a step of moving the tool in the cutting-feed mode along the curve of the external
shape from the machining starting point P
i on the cutting path PT
i to a machining starting point P
i+1 on a next cutting path PT
i+1' a step of moving the tool in the cutting-feed mode along the cutting path PT
i+1 to execute cutting along the cutting path PT
i+1' and a step of repeating each of these steps to perform area cutting. According to
this area cutting method, all movement along the Z axis is performed in the rapid-traverse
mode, thereby enabling the time required for area cutting to be reduced.
Brief Description of the Drawings
[0008] Fig. 1 is a view for describing the conventional area cutting method, Fig. 2 is a
view of tool shape, Fig. 3 is a view for describing a method of moving a tool to a
starting point P in a cut-in direction, Fig. 4 is a view for describing tool overlap
when a tool is moved along i-th and (i+l)th cutting paths, Fig. 5 is a view for describing
the present invention in general terms, Fig. 6 is a block diagram of an embodiment
of the present invention, Fig. 7 is flowchart of processing for implementing the area
cutting method of the present invention, Fig. 8 is a view for describing offset processing,
Fig. 9 is a view for describing path processing for moving a tool along the curve
of an external shape, and Fig. 10 is a flowchart of processing for creating NC data
for area cutting.
Best Mode for Carrying Out the Invention
[0009] Fig. 5 is a view for describing the present invention in general terms. The present
invention is an area cutting method for moving a tool TL in a predetermined direction
(direction of arrow A) along a cutting path PT
i to machine the interior of an area, thereafter moving the tool in a direction identical
with that of the aforementioned direction (direction of arrow A) along the next cutting
path PT
i+1' which is shifted by a predetermined amount P, to machine the interior of the area,
and repeating these unidirectional cutting motions to machine an area AR bounded by
the curve OLC of a predetermined external shape. The area cutting method has a step,
executed after completion of cutting along the cutting path PT
i, of moving a tool in the cutting-feed mode along the curve OLC of the external shape
from a machining end point Q
i on the cutting path PT. to a machining end point Q
i-1 on a cutting path PT
i-1 cut last, a step of positioning the tool at a machining starting point P
i on the cutting path PT
i, a step of moving the tool in the cutting-feed mode along the curve of the external
shape from the machining starting point P
i on the cutting path PT
i to a machining starting point P
i+l on the next cutting path PT
i+1, a step of moving the tool in the cutting-feed mode along the cutting path PT
i+l to execute cutting along the cutting path PT
i+1, and a step of repeating each of these steps to perform area cutting.
[0010] Fig. 6 is a block diagram of an embodiment of the present invention, and Fig. 7 is
a flowchart of processing according to the present invention. The area cutting method
of the present invention will now be described in accordance with Figs. 5, 6 and 7.
(1) When a cycle start button on an operator's panel 101 is pressed, a processor 102
causes an NC data reader 103 to read one block of NC data from an NC tape 104. The
NC tape 104 stores area cutting data in addition to ordinary path data, G-function
instruction data and M-, S- and T-function instruction data. Stored at the end of
the NC program is an M code (M02) indicating program end. Placed at the beginning
of the area cutting data is an area cutting command indicating that the data which
follow are the area cutting data. Placed at the end of the area cutting data is a
code indicative of the end of the area cutting data.
(2) The processor 102, placed under the control of a control program stored in a ROM
105, checks whether an item of the read NC data is "M02", which is indicative of program
end. If the item of data is "M02", numerical control processing is ended.
(3) If the item of read NC data is not "M02" indicative of program end, then the processor
102 checks whether the item of NC data is the area cutting command.
(4) If the item of NC data is not the area cutting command, the processor 102 executes
ordinary numerical control processing.
[0011] By way of example, if an item of NC data is an M-, S- or T-function instruction,
the processor delivers the data to a machine tool 107 via an interface circuit 106
between an NC unit and the machine. When the machine tool 107 generates a completion
signal indicating completion of processing for the M-, S- or T-function instruction,
the processor causes the NC data reader 103 to read the next item of NC data.
[0012] If the item of NC data is path data, then the following path control processing is
executed. Specifically, the processor obtains incremental values X
i, Y
i, Z. along the respective axes, obtains velocity components F , F , F along the respective
axes from equations



based on the incremental values and a commanded feed velocity F, thereafter obtains
travelling quantities
ΔX,
ΔY,
ΔZ, which are to be traversed along the respective axes in a predetermined period of
time
ΔT seconds (= 8 msec), from equations
[0013] 


The processor delivers
ΔX,
ΔY,
ΔZ to a pulse distributor 108 every
ΔT sec. On the basis of the input data (
ΔX,
ΔY,
ΔZ), the pulse distributor 108 performs a simultaneous three-axis pulse distribution
calculation to generate distributed pulses X
p, Yp, Zp. The distributed pulses are applied as inputs to servo circuits 109X, 109Y,
109Z for the respective axes to rotate servomotors 110X, 110Y, 110Z. The tool is thus
moved relative to the workpiece toward a target position.
[0014] The processor 102, in accordance with the following formulae, updates the present
position X , Y
a Z
a along the respective axes every ΔT sec, X , Y
a, Z
a having been stored in a working memory 112:
[0015] 


The sign depends upon the direction of movement. Similarly, in accordance with the
following formulae, the processor 102 updates remaining traveling distances X
r, Y
r, Z
r (the initial values of which are the incremental values X
i, Y
i, Z
i, respectively) every
ΔT sec, X
r, Y
r, Z
r having been stored in the working memory 112:
[0017] When the following condition is established:

the processor 102 then causes the NC data reader 103 to read the next item of NC data.
[0018] (5) If the item of NC data is found to be the area cutting command at the decision
step (3), the processor 102 causes the NC data reader 103 to read the area cutting
data and store the data in a RAM 111 until the code indicating the end of the area
cutting data is read out. It should be noted that the area cutting data are (1) data
indicating the curve of the external shape of the area, (2) cutting direction data
(data indicating that the tool is to be moved in the direction of the arrow A or in
the direction of an arrow D in Fig. 5), (3) cut-in direction data (data indicating
that the tool is to be moved in the direction of the arrow B or in the direction of
an arrow C in Fig. 5), (4) pitch P in the cut-in direction, (5) cutting velocity,
(6) coordinate values of a starting point P in the cut-in direction, (7) coordinate
values of an end point P in the cut-in direction, (8) the position of an approach
plane, and the like. Hereafter we will assume that the cutting direction is the -X
direction, that the cut-in direction is the +Y direction, that the approach plane
is parallel to the XY plane at a height ZA, that the coordinate values of the cut-in
direction starting point P
s are (X
s,Y
s), and that the coordinate values of the cut-in direction end point P
e are (X
e,Y
e). (6) When the reading of the area cutting data ends, the processor 102 calculates
the curve OFC (Fig. 5), which is offset from the curve OLC of the external shape by
a distance D (= ra+t), the latter being obtained by adding the tool radius ra and
the finishing tolerance t. It should be noted that the tool radius r
a is obtained by reading a radius value corresponding to a commanded tool number from
an offset memory 113, which stores the correspondence between tool numbers and tool
radii. The offset curve OFC is found through the following processing. Specifically,
as shown in Fig. 8, let two straight lines specifying the curve OLC of the external
shape be Sl and S2. Straight lines Sl', S2' offset from the straight lines Sl, S2,
respectively, by the distance D are found. The intersection P2 of the straight lines
Sl', S2' is then found. The intersection P2 is one point specifying the offset curve
OFC. Accordingly, if points of intersection are found in a similar manner and stored
in the RAM 111, the offset curve OFC will be obtained.
[0019] (7) When an offset point P
s' [Fig. 5(A)] corresponding to the cut-in direction starting point P
s is found by offset calculation, the tool TL is moved from the initial position and
positioned at an approach point near the offset point P ', then the tool is moved
obliquely toward the workpiece from the approach point in the cutting-feed mode and
is positioned at the offset point P
s', just as in the conventional method. (This is approach processing.)
[0020] (8) When the tool arrives at the offset point P
s', the processor 102 initializes i, which is stored in the working memory 112, to
1, and sets the offset point P
s' to the machining starting point P
i-1 (= P
o) and to the machining end point Q
i-1 (= Q
o) on the (i-l)th (Oth) cutting path
[0021] 

(9) Next, the processor 102 performs processing for specifying an i-th cutting path
PT
i. Specifically, the processor 102 creates the straight line SL
i. The straight line SL
i is expressed by the equation

where Y
s' is the coordinate of P
s' along the Y axis.
[0022] (10) Thereafter, the processor 102 calculates the coordinate values of the points
P
i, Q
i where the straight line SL
i intersects the offset curve OFC. Of the intersection points P
i, Q
i, that which has the larger X coordinate value is treated as the machining starting
point, and that which has the smaller X coordinate value is treated as the machining
end point.
[0023] (11) When the two intersection points P
i, Q
i specifying the i-th cutting path PT
i have been found, the processor 102 performs path processing for moving the tool in
the cutting-feed mode along the curve OLC (offset curve OFC) of the external shape
from the ma-
chi
ni
ng starting point P
i-1 of the (i-l)th cutting path PT
i-1 to the machining starting point P
i of the cutting path PT
i. It should be noted that the offset curve is composed of a number of straight lines
and circular arcs (each of which is referred to as an element). Therefore, in a case
where the points P
i-1' P
i both lie. on the same element (straight line EL, circular arc
EA), as shown in Figs. 9(A), (B), path processing des- c
ribed at step (4) is executed with the points P
i-1, Pi serving as the starting and end points, respectively. If the points P
i-1, P
i do not lie on the same element, as shown in Fig. 9(C), first path processing, in
which the point P
i-1 and an end point Q
e of an element EL
1 on which the point P
i_1 lies serve as the starting and end points, respectively, and second path processing,
in which a starting point Q
s (= Q
e) on an element EL
2 on which the point P
i lies and the point P
i serve as the starting and end points, respectively, are executed in the same manner
as the path processing of step (4).
[0024] (12) When the tool arrives at the machining starting point P
i on the cutting path PT
i, the processor 102 executes the path processing of step (4) to move the tool from
the point P
i to the point Q
i in the cutting-feed mode, thereby to execute cutting along the cutting path PT
i.
[0025] (13) Upon the completion of cutting, the processor 102 executes path processing for
moving the tool in the cutting-feed mode along the offset curve OFC from the machining
end point Q
i of the i-th cutting path PT
i to the machining end point Q
i-1 of the cutting path PT
i cut last. It should be noted that the path processing is performed in the same manner
as step (11).
[0026] (14) Next, the processor 102 moves the tool by the amount ZA in the rapid-traverse
mode along the +Z axis, thereafter moves the tool in the rapid-traverse mode along
the approach plane to a point P
i' [see Fig. 5(
B)] directly above the machining starting point P
i of the cutting path PT
i, and then positions the tool at the point P
i in rapid traverse or at a velocity (much higher than cutting-feed velocity) slightly
lower than the rapid-traverse velocity.
[0027] (15) When the tool has been positioned at P
i, the processor 102 obtains the difference

between the present position coordinate (stored in the working memory 112) Y a along
the Y axis and the Y-axis coordinate Y
e' of the point P
e' offset from the cut-in direction end point P
e and checks whether or not the difference is greater than the pitch P.
[0028] (16) If
ΔY ≥ P holds, the processor 102 performs the operation

and repeats the processing from step (9) onward.
[0029] (17) If
ΔY < P holds, then the processor 102 performs area cutting by moving the tool along
the offset curve OFC from the machining starting point P
i to the machining end point Q
i of the cutting path PT
i.
[0030] Though the foregoing description relates to a case where the shape of the area is
that shown in Fig. 5, the present invention is not limited thereto and can be applied
to areas of various shapes.
[0031] Further, in the case described above, an area cutting command is inserted into the
NC tape, cutting paths are successively created by using the area cutting data that
follow the area cutting command, and area cutting is performed by moving the tool
along the cutting paths. However, the invention is not limited to such case, for an
arrangement can be adopted in which an NC tape (NC data) is created by the aforementioned
method and the NC tape is loaded in an NC unit so that area cutting may be performed.
Fig. 10 is a flowchart of processing for creating an NC tape for area cutting. The
NC data creation processing is almost the same as the processing from step (5) onward
in Fig. 7, the only difference being that NC data for cutting or for positioning is
created instead of moving the tool.
Industrial Applicability
[0032] As described above, the present invention is arranged to move a tool in the cutting-feed
mode along a curve OLC of an external shape from a machining end point Q on a cutting
path PT
i just cut to a machining end point Q
i-1 on a cutting path PT
i-1 cut last, thereafter position the tool in the rapid-traverse mode at a machining
starting point P
i on the cutting path PT
i, then move the tool in the cutting-feed mode along the curve of the external shape
from the point P
i to a machining starting point P
i+l on the next cutting path PT
i+1' and subsequently repeat the above-described cycle to perform area cutting. Therefore,
all movement (retraction motion, approach motion) along the Z axis is performed in
the rapid-traverse mode and final tool movement along the curve of the external shape
is dispensed with without leaving uncut portions. This enables the time required for
area cutting to be curtailed.
1. An area cutting method for moving a tool TL in a predetermined direction along
a cutting path PTi to machine the interior of an area, thereafter moving the tool in a direction identical
with that of said direction along the next cutting path PTi+1, which is shifted by a predetermined amount, to machine the interior of the area,
and repeating these unidirectional cutting motions to machine an area bounded by a
curve of a predetermined external shape, characterized in that the area is machined
by repeating a first step, executed after completion of cutting along the cutting
path PTi, of moving a tool in a cutting-feed mode along the curve of the external shape from
a machining end point Q. on said cutting path PTi to a machining end point Qi-1 on a cutting path PTi-1 cut last, a second step of positioning the tool from the point Qi-1 to a machining starting point Pi on the cutting path PTi, a third step of moving the tool in the cutting-feed mode along the curve of the
external shape from the machining starting point Pi on the cutting path PTi to a machining starting point Pi+1 on the next cutting path PTi+1, and a fourth step of moving the tool in the cutting-feed mode along the cutting
path PTi+1 to execute cutting along said cutting path PTi+1.
2. An area cutting method according to claim 1,
characterized in that the positioning in said second step is executed in a rapid-traverse
mode.
3. An area cutting method according to claim 1, characterized by having a step of
entering data necessary for area cutting.
4.. An area cutting method according to claim 3,
characterized by having steps of including cutting path shift direction and an amount
of cutting path shift in said area cutting data in advance, obtaining from said shift
direction and amount of shift a straight line specifying the next cutting path PTi+1, and adopting two points at which said straight line intersects an offset curve offset
a predetermined amount from the curve of the external shape as machining starting
and end points Pi+1' Qi+1' respectively, of the cutting path PTi+1.
5. An area cutting method according to claim 4,
wherein said second step has a step of raising the tool in the rapid-traverse mode
up to an approach plane specified by the area cutting data, a step of moving the tool
on said approach plane in the rapid-traverse mode to a point directly above the point
Pi, and a step of moving the tool in the rapid-traverse mode to the point Pi.
6. An area cutting method according to claim 1,
characterized by having a step of determining whether a remaining cut-in width is
smaller than said predetermined value specified by the area cutting data, and moving
the tool in the cutting-feed mode along the curve of the external shape from the point
Pi to the point Qi when the remaining cut-in width is smaller than said predetermined value.
7. An area cutting method for moving a tool TL in a predetermined direction along
a cutting path PTi to machine the interior of an area, thereafter moving the tool in a direction identical
with that of said direction along the next cutting path PTi+1' which is shifted by a predetermined amount, to machine the interior of the area,
and repeating these unidirectional cutting motions to machine an area bounded by a
curve of a predetermined external shape, characterized by having a first step of creating
NC data for moving the tool in a cutting-feed mode along the curve of the external
shape from a machining end point Qi on an i-th cutting path PTi to a machining end point Qi-1 on an (i-l)th cutting path PTi-1 cut last, a second step of creating positioning data for positioning the tool in
a rapid-traverse mode from the point Qi-1 to a machining starting point Pi on the cutting path PTi, a third step of creating NC data for moving the tool in the cutting-feed mode along
the curve of the external shape from the machining starting point Pi on the cutting path PTi to a machining starting point Pi+1 on the next cutting path PTi+1' a fourth step of creating NC data for moving the tool in the cutting-feed mode along
the cutting path PTi+1, and a fifth step of repeating each of these steps to create all NC data for area
cutting, and performing area cutting by using said NC data.
8. An area cutting method according to claim 7,
characterized by having a step of entering data necessary for area cutting.
9. An area cutting method according to claim 8,
characterized by having steps of including cutting path shift direction and an amount
of cutting path shift in said area cutting data in advance, obtaining from said shift
direction and amount of shift a straight line specifying the next cutting path PTi+1' and adopting two points at which said straight line intersects an offset curve offset
a predetermined amount from the curve of the external shape as machining starting
and end points Pi+1, Qi+1, respectively, of the cutting path PTi+1.
10. An area cutting method according to claim 9,
wherein said second step comprises creating NC data for raising the tool in the rapid-traverse
mode up to an approach plane specified by the area cutting data, NC data for moving
the tool on said approach plane in the rapid-traverse mode to a point directly above
the point P., and NC data for moving the tool in the rapid-traverse mode to the point Pi.
ll. An area cutting method according to claim 7,
characterized by having a step of determining whether a remaining cut-in width is
smaller than said predetermined value specified by the area cutting data, and creating
NC data for moving the tool in the cutting-feed mode along the curve of the external
shape from the point Pi to the point Qi when the remaining cut-in width is smaller than said predetermined value.